Wing flap with torque member and method for forming thereof

ABSTRACT

A wing flap includes a flap body and a torque member. The torque member is integrally formed with at least a portion of the flap body.

FIELD

The present disclosure is generally related to aircraft and, moreparticularly, to an aircraft wing flap having a torque member that isintegrally formed with at least a portion of a flap body and a methodfor forming the wing flap.

BACKGROUND

Fixed-wing aircraft typically include various flight control surfacesthat enable adjustment and control of the aircraft's flight. Forexample, flaps mounted on trailing edges of wings modify the effectivecontour of the wings and, thus, modify the lift characteristics of thewings. In certain types of flap systems, an inboard flap includes atorque member that is used to move the flap between stowed and deployedpositions. Typically, the torque member extends into the side of thefuselage, or into a wing fairing structure of the fuselage, and iscoupled to a flap support mechanism that controls movement of the flap.

In many flap systems, the torque member is a tubular structure having acircular cross-sectional shape, commonly referred to as a torque tube.The torque tube is typically coupled to a structural member of the flap,such as an inboard rib. However, achieving appropriate structural andload-bearing performance can require a heavy torque tube and large andcomplex couplings that increase the weight and cost of the aircraft.Additionally, some flap systems utilize a failsafe torque tube thatincludes a dual torque tube design that further increases the cost,weight, and complexity of the aircraft.

Accordingly, those skilled in the art continue with research anddevelopment efforts in the field of aircraft wing flap actuation.

SUMMARY

In an example, the disclosed wing flap includes a flap body and a torquemember being integrally formed with at least a portion of the flap body.

In an example, the disclosed wing of an aircraft includes a wing bodyand a wing flap. The wing flap includes a flap body movably coupled tothe wing body and a torque member being integrally formed with at leasta portion of the flap body.

In an example, the disclosed method includes a step of integrallyforming a torque member with at least a portion of a flap body to form awing flap. The flap body is configured to be movably coupled with a wingof an aircraft. The torque member is configured to be coupled to a flapactuator of the aircraft.

Other examples of the disclosed wing flap and method will becomeapparent from the following detailed description, the accompanyingdrawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic, perspective view of an example of an aircraft;

FIG. 2 is a schematic, perspective view of an example of a wing of theaircraft;

FIG. 3 is a schematic, perspective view of an example of a disclosedwing flap;

FIG. 4 is a schematic, interior, perspective view of an example of aportion of the aircraft showing an example of a torque member of thedisclosed wing flap extending through an opening in a fuselage of theaircraft;

FIG. 5 is a schematic, partial, perspective view of an example of thedisclosed wing flap;

FIG. 6 is a schematic, elevation, cross-sectional view of an example ofa disclosed wing flap;

FIG. 7 is a schematic, partial, plan view of an example of the disclosedwing flap;

FIG. 8 is a schematic, plan view of an example of the disclosed wingflap;

FIG. 9 is a schematic, partial, plan view of an example of the disclosedwing flap;

FIG. 10 is a schematic, partial, plan view of an example of thedisclosed wing flap;

FIG. 11 is a schematic, partial, plan view of an example of thedisclosed wing flap;

FIG. 12 is a schematic, partial, plan view of an example of thedisclosed wing flap;

FIG. 13 is a schematic, partial, plan view of an example of thedisclosed wing flap;

FIG. 14 is a schematic, partial, plan view of an example of thedisclosed wing flap;

FIG. 15 is a schematic, partial, plan view of an example of thedisclosed wing flap;

FIG. 16 is a schematic, partial, plan view of an example of thedisclosed wing flap;

FIG. 17 is a schematic, partial, plan view of an example of thedisclosed wing flap;

FIG. 18 is a schematic, partial, plan view of an example of thedisclosed wing flap;

FIG. 19 is a schematic, perspective view of an example of the disclosedwing flap;

FIG. 20 is a flow diagram of an example of a disclosed method; and

FIG. 21 is a flow diagram of an example aircraft production and servicemethodology.

DETAILED DESCRIPTION

The following detailed description refers to the accompanying drawings,which illustrate specific examples described by the disclosure. Otherexamples having different structures and operations do not depart fromthe scope of the present disclosure. Like reference numerals may referto the same feature, element, or component in the different drawings.

Illustrative, non-exhaustive examples, which may be, but are notnecessarily, claimed, of the subject matter according the presentdisclosure are provided below.

FIG. 1 is an illustrative example of an aircraft 200. In theillustrative example, the aircraft 200 is a fixed-wing aircraft. Theaircraft 200 includes a fuselage 202, a pair of wings 214 (also referredto individually as wing 214), and a propulsion system 216. The aircraft200 also includes a plurality of high-level systems, such as, but notlimited to, an electrical system 226, a hydraulic system 228, and/or anenvironmental system 230. Any number of other systems may also beincluded.

The fuselage 202 is the main body of the aircraft 200 and includes anysuitable central structure configured to hold a crew, one or morepassengers, and/or cargo. In the illustrative example, the fuselage 202is an elongate, generally cylindrical fuselage. The fuselage 202includes a nose portion at a forward end of the fuselage 202 and a tailportion at an aft end of the fuselage 202. As used herein, the terms“forward” and “aft” have their ordinary meaning as known to thoseskilled in the art and refer to positions relative to a direction ofmovement of the aircraft 200. The tail portion may also include avertical stabilizer 240 and horizontal stabilizers 238.

The fuselage 202 includes an airframe 222 that defines an interior 224,which may include a passenger compartment and/or a cargo compartment. Awing fairing structure 220 (e.g., fuselage/wing fairing) may also beprovided at each interface between the fuselage 202 and the wing 214 andmay extend from proximate (at or near) the fuselage 202 to proximate thewing 214 associated therewith.

The wings 214 include any suitable airfoil structures that areconfigured to provide lift to the aircraft 200. In the illustrativeexample, the wings 214 are elongate structures extending from a lowerportion of the fuselage 202 in a swept wing, tapered planform. In otherexamples, the wings 214 are straight or delta-shaped. In still otherexamples, the wings 214 are trapezoidal, constant, elliptical,semi-elliptical, or other configurations known in the art.

In the illustrative example, the propulsion system 216 includes twoturbofan engines mounted to the wings 214, for example, by pylons. In anexample, each engine is housed in a nacelle, which includes an inlet anda nozzle. In other examples, the engines may be mounted to the fuselage202 or other aircraft structures, such as the tail portion. In variousother examples, the propulsion system 216 may include more or fewerengines and other types of engines (e.g., turboprop engines) may beused.

The aircraft 200 includes various flight control surfaces 232. Theflight control surfaces 232 include any pivoting aerodynamic device thatis used to adjust and control flight and aerodynamic characteristics ofthe aircraft 200. Examples of the flight control surfaces 232 include aninboard flap 208 and/or an outboard flap 218 that are located on thetrailing end of the wings 214, an elevator 234 that is located on thetrailing end of the horizontal stabilizers 238, a rudder 236 that islocated on the trailing end of the vertical stabilizer 240, and othercontrol surfaces, such as leading end flaps, ailerons, and spoilers. Asused herein, the terms “inboard” and “outboard” have their ordinarymeaning as known to those skilled in the art and refer to positionsrelative to a center line of the aircraft 200.

In an example, the inboard flap 208 (also referred to collectively asinboard flaps 208) and/or the outboard flap 218 (also referred tocollectively as outboard flaps 218) include any suitable structuremounted on the trailing edge of the wing 214 and configured to pivot,rotate, and/or translate (e.g., forward and aft) relative to the wing214. The inboard flaps 208 and/or the outboard flaps 218 are configuredto alter the lift characteristics of the wing 214. The inboard flaps 208and/or the outboard flaps 218 are movable between at least a raised(stowed, retracted, or “flaps up”) position and a lowered (deployed,extended, or “flaps down”) position. In an example, the inboard flaps208 and/or the outboard flaps 218 are pivotable about a fixed axis. Inan example, the inboard flaps 208 and/or the outboard flaps 218 pivotthrough a predetermined path, which is generally arcuate of curved.

In an example, the aircraft 200 also includes a flap actuator 260. Theflap actuator 260 is associated with each wing 214 for actuating theinboard flap 208. In an example, the flap actuator 260 includes amotorized arm that is located, or housed, within the fuselage 202, orthe wing fairing structure 220.

In an example, a torque member 210 couples the flap actuator 260 withthe associated inboard flap 208 to transfer an actuating/de-actuating(e.g., lowering/raising) force from the flap actuator 260 to theassociated inboard flap 208. The torque member 210 extends through anopening 206 in the aircraft 200 (e.g., an opening 206 in the fuselage202 or the wing fairing structure 220). The opening 206 in the aircraft200 is sized and shaped to accommodate a travel path of the torquemember 210 as the inboard flap 208 is lowered and raised.

FIG. 2 is an illustrative example of the wing 214. The wing 214 is anyone of various wing structures that includes a wing body 258. The wingbody 258 is formed of various structural members including, but notlimited to, an upper wing skin 246, a lower wing skin 248, a pluralityof wing spars 250 that extend between the upper wing skin 246 and thelower wing skin 248, and a plurality of wing ribs 252 that extendbetween the upper wing skin 246 and the lower wing skin 248. Thesestructural members are coupled together by any one of various methodsincluding, but not limited to, connection by various kinds of fasteners,co-curing, or integrally forming. The wing spars 250 extend in aspan-wise direction between a wing root 254 of the wing 214 and a wingtip 256 of the wing 214. The wing ribs 252 extend in a chord-wisedirection between a leading edge 244 of the wing 214 and a trailing edge242 of the wing 214. The wing 214 further includes a wing flap 100. Anexample of the disclosed wing flap 100 is movably coupled with the wing214 at the trailing edge 242 of the wing 214 proximate to the wing root254.

Referring to FIGS. 3-19, disclosed are various examples of the wing flap100. The disclosed wing flap 100 includes a flap body 164 and a torquemember 108 that is integrally formed with at least a portion of the flapbody 164. The torque member 108 extends from the inboard end 124 of theflap body 164 in an inboard direction. As used herein, the phrase“integrally formed” refers to parts (e.g., constituents or components)being of, pertaining to, or belonging as a part of a unitary whole, inwhich the parts are organically joined or linked during formation toform the unitary whole, and requires more than mere interconnectedparts.

In an example, the torque member 108 is integrally formed with at leastone structural member 198 (FIGS. 6 and 7) of the flap body 164. As usedherein, the phrase “structural member,” with reference to any one of aplurality of structural members 198 that partially form the wing flap100, refers to a load-bearing element that is configured to carry a loador react to stresses applied to the wing flap 100. Generally, thestructural members 198 that partially form the wing flap 100 include,but are not limited to, spars, ribs, stringers, and the like. Forexample, the flap body 164 and the torque member 108 share a commonstructural member 198, such as a spar 106 that extends along the wingflap 100 in a span-wise direction. In an example, the flap body 164includes outer skins (e.g., an upper skin 102 and a lower skin 104) anda plurality of spars 106 and the torque member 108 is integrally formedby a portion of at least one of the plurality of spars 106 that extendsfrom the flap body 164 in an inboard direction. Accordingly, and asdiscussed in more detail below, the wing flap 100 includes the upperskin 102 and the lower skin 104. The wing flap 100 further includes aplurality of spars 106 extending between the upper skin 102 and thelower skin 104.

The torque member 108 being integrally formed with at least a portion ofthe flap body 164 may reduce the cost, complexity, and/or weight of thewing flap 100 by utilizing a portion of the existing structure of theflap body 164 to form at least a portion of the torque member 108. As anexample, the torque member 108 being integrally formed with at least aportion of the flap body 164 may reduce the complexity and coststypically associated with coupling a torque member, such as aconventional torque tube, with an inboard flap of an aircraft wing. Forexample, forming the torque member 108 from a portion of an existingstructural member 198 (e.g., a spar 106) of the wing flap 100 is lesscostly than fabricating a metal (e.g., titanium or steel) torque tube,reduces the components and time as compared to that required to assembleand join the metal torque tube to the wing flap, and reducesconcentrated loading locations formed at joints.

As another example, the torque member 108 being integrally formed withat least a portion of the flap body 164 may reduce the weight of theaircraft wing and reduce the costs associated with production of theaircraft wing and/or the aircraft. For example, forming the torquemember 108 from a portion of an existing structural member 198 (e.g., aspar 106) of the wing flap 100 requires fewer joints than coupling themetal torque tube to the wing flap. As another example, forming thetorque member 108 from a portion of an existing structural member 198made of carbon fiber reduces a risk of corrosion and offers increasesdurability as compared to a metal torque tube. As yet another example,the torque member 108 being integrally formed with at least a portion ofthe flap body 164 is stiffer than the metal torque tube that is coupledto the wing flap, which advantageously reduces structural deflection.

The wing flap 100 is an example of the inboard flap 208 of the wing 214of the aircraft 200 and the torque member 108 is an example of thetorque member 210 of the inboard flap 208 (FIG. 1). In other examples,the teachings of the present disclosure may be applied to one or moreother flight control surfaces 232 of the aircraft 200.

In an example, the wing flap 100 includes any suitable pivotingstructure that is mounted on, or is otherwise movably coupled with, thewing body 258 of the wing 214 at the trailing edge 242 of the wing 214(FIGS. 1 and 2). In an example, the wing flap 100 is located adjacent tothe wing fairing structure 220 of the fuselage 202 of the aircraft 200.During operation of the wing flap 100, the wing flap 100 is movablebetween at least a raised (stowed, retracted, or “flaps up”) positionand a lowered (deployed, extended, or “flaps down”) position to alterthe lift characteristics of the wing.

Referring to FIG. 3, the flap body 164 includes an inboard end 124 andan outboard end 126 opposite the inboard end 124. The flap body 164 alsoincludes a leading end 112 and a trailing end 116 opposite the leadingend 112. The torque member 108 includes an inboard end 180 and anoutboard end 178 opposite the inboard end 180. In an example, the torquemember 108 is integrated with the inboard end 124 of the flap body 164and extends outward from the inboard end 124 of the flap body 164 in aninboard direction.

In an example, the torque member 108 is located toward or proximate to(e.g., at or near) the leading end 112 of the flap body 164. In anexample, the torque member 108 is located toward or proximate to thetrailing end 116 of the flap body 164. In an example, the torque member108 is located between the leading end 112 and the trailing end 116 ofthe flap body 164, such as proximate to a middle portion of the flapbody 164.

In an example, the torque member 108 has a cross-sectional shape that atleast partially matches, or matches a portion of, a cross-sectionalshape of the flap body 164 as viewed from the inboard end 124. Thecross-sectional shape of the torque member 108 at least partiallymatching the cross-sectional shape of the flap body 164 at the inboardend 124 of the flap body 164 may reduce complexity associated withcoupling the torque member 108 to the flap body 164 and may reduce theimpact the torque member 108 has on the aerodynamic characteristics ofthe wing flap 100 and/or the aircraft 200. As used herein, componentshaving at least partially matching cross-sectional shapes may have, butdo not require, matching sizes and/or dimensions.

In an example, the torque member 108 has a non-circular cross-sectionalshape. As an example, the torque member 108 has a polygonalcross-sectional shape. In the illustrative example, the torque member108 has a rectangular cross-sectional shape. In another illustrativeexample, the torque member 108 has a cross-sectional shape including acombination of linear and arcuate sides, such as three substantiallylinear sides and a fourth arcuate side connecting two linear sides toform a generally rectangular cross-sectional shape.

In an example, the torque member 108 includes, or is at least partiallyformed by, a front wall 156, a rear wall 158 that is opposite the frontwall 156, an upper wall 160, and a lower wall 162 that is opposite theupper wall 160. At least one of the front wall 156, the rear wall 158,the upper wall 160, and the lower wall 162 is integrally formed with theflap body 164. In an example, at least one of the upper wall 160 and thelower wall 162 has a profile shape that matches a portion of the flapbody 164 as viewed from the inboard end 124.

A profile shape of each one of the front wall 156, the rear wall 158,the upper wall 160, and the lower wall 162, as viewed from the inboardend 124, defines the cross sectional shape of the torque member 108. Inan example, the profile shape of one or more of the front wall 156, therear wall 158, the upper wall 160, and the lower wall 162 is planar. Inan example, the profile shape of one or more of the front wall 156, therear wall 158, the upper wall 160, and the lower wall 162 is curved.

Referring to FIG. 4, the flap body 164 of the wing flap 100 is actuatedor moved between the raised and lowered positions by way of the torquemember 108, which extends through the opening 206 formed in the fuselage202. The opening 206 is configured to enable a full range of motion forthe torque member 108 and the associated flap body 164 during operation.In an example, the flap actuator 260 includes a flap support mechanism212, also commonly referred to as a flap carriage mechanism, and amotorized actuator (not shown) that is operatively coupled with the flapsupport mechanism 212. In an example, the inboard end 180 of the torquemember 108 is coupled to the flap support mechanism 212.

FIG. 4 shows the wing flap 100 in a generally raised position with thetorque member 108 extending through the opening 206 in the fuselage 202and coupled to the flap support mechanism 212. In an example, the torquemember 108 is configured to rotate, or is configured to be rotated,about an axis of rotation 184 to pivot or rotate the flap body 164relative to the wing 214. Alternatively, or in addition to, in anexample, the torque member 108 is configured to translate, or isconfigured to be translated, forward and aft along a travel path 186 tomove the flap body 164 between a forward/raised position and anaft/lowered position. In an example, the travel path 186 is arcuate and,thus, the opening 206 is elongate and arcuate to enable a full range ofmotion of the wing flap 100 (the torque member 108 and the flap body 164associated therewith) during operation. Rotation of torque member 108enables the flap body 164 to pivot about the axis of rotation 184 duringactuation of the wing flap 100. In an example, the axis of rotation 184is a central longitudinal axis of the torque member 108.

In an example, the torque member 108 also includes a mounting flange 182that is located at the outboard end 178 of the torque member 108 andthat is configured to be coupled to the flap support mechanism 212. Inan example, the flap support mechanism 212 includes a carrier mechanism262, which is also commonly referred to as a carrier beam. The carriermechanism 262 is coupled to the inboard end 180 of the torque member 108and transfers motion to the torque member 108 during actuation of theflap support mechanism 212. In an example, the carrier mechanism 262includes one or more link members that are pivotally coupled to themounting flange 182 to enable rotational and translational movement ofthe torque member 108, in which an instantaneous center of rotation ofthe torque member 108 varies along the travel path 186.

Referring to FIG. 5, in an example, the wing flap 100 includes aninboard flap fairing 190 that is coupled to the flap body 164 proximateto the inboard end 124 of the flap body 164. The inboard flap fairing190 moves with the wing flap 100 relative to the fuselage 202 duringactuation of the wing flap 100. In an example, the wing flap 100 alsoincludes a door 188 that is coupled to the torque member 108. The door188 moves with the torque member 108 and is located relative to thefuselage 202 such that the door 188 covers at least a portion of theopening 206 (FIG. 4) in the fuselage 202 during actuation of the wingflap 100.

Referring to FIGS. 6-8, in an example, the wing flap 100 includes anupper skin 102 (the upper skin 102 is not shown in FIGS. 7 and 8), alower skin 104 that is opposite the upper skin 102, and a plurality ofspars 106 (also referred to individually as spar 106 and collectively asspars 106) that extend between the upper skin 102 and the lower skin104. In an example, the torque member 108 is integrally formed with atleast one of the spars 106. In an example, the torque member 108 isintegrally formed with at least one of the upper skin 102 and the lowerskin 104.

In an example, the upper skin 102 and/or the lower skin 104 arepermanently coupled with the spars 106. As examples, one or both of theupper skin 102 and the lower skin 104 may be connected to the spars 106by various kinds of fasteners (not shown), the spars 106 may be co-curedwith one or both of the upper skin 102 and/or the lower skin 104, thespars 106 may be structurally bonded (e.g., adhesively bonded) with oneor both of the upper skin 102 and/or the lower skin 104, or acombination thereof.

Referring to FIG. 6, in an example, each one of the spars 106 includesan upper spar cap 170, a lower spar cap 172 that is opposite the upperspar cap 170, and a spar web 174 that extends between the upper spar cap170 and the lower spar cap 172. The upper spar cap 170 is coupled to theupper skin 102 and the lower spar cap 172 is coupled to the lower skin104. Each one of the spars 106 has one of various cross-sectional shapesdefined by the relative configuration of the upper spar cap 170, thelower spar cap 172, and the spar web 174. In an example, at least one ofthe spars 106 has a constant cross-sectional shape along a longitudinalaxis of the spar 106. In an example, at least one of the spars 106 has avariable, or non-constant, cross-sectional shape along the longitudinalaxis of the spar 106.

In an example of the spar 106, one end of the spar web 174 is connectedto an end of the upper spar cap 170 and the other end of the spar web174 is connected to an end of the lower spar cap 172 and both the upperspar cap 170 and the lower spar cap 172 project from the same side ofthe spar web 174 (commonly referred to as having a C-shape or U-shape incross-section).

In an example of the spar 106, one end of the spar web 174 is connectedto a middle portion of the upper spar cap 170 (e.g., between the ends ofthe upper spar cap 170) and the other end of the spar web 174 isconnected to a middle portion of the lower spar cap 172 (e.g., betweenthe ends of the lower spar cap 172) and both the upper spar cap 170 andthe lower spar cap 172 project from the both sides of the spar web 174(commonly referred to as having a I-shape or H-shape in cross-section).

Referring to FIGS. 7 and 8, the torque member 108 of the disclosed wingflap 100 is at least partially formed by an integrally formed extensionof at least one structural member 198 (FIG. 7) of the wing flap 100 thatalso at least partially forms the flap body 164. In an example, at leastone of the spars 106 includes a spar major portion 148 and a sparextension portion 150 that extends coaxially from the spar major portion148. The flap body 164 is partially formed by the spar major portion 148of the at least one of the spars 106 and the torque member 108 ispartially formed by the spar extension portion 150 of the at least oneof the spars 106. In an example, the spar major portion 148 and the sparextension portion 150 have the same cross-sectional shape and the samedimensions. In an example, the spar major portion 148 and the sparextension portion 150 have different same cross-sectional shapes and/ordifferent dimensions.

In an example, the spar major portion 148 extends in a span-wisedirection between the outboard end 126 of the flap body 164 and theinboard end 124 of the flap body 164. The spar major portion 148 is astructural member, or load-bearing element, of the flap body 164. Thespar extension portion 150 extends from the inboard end 124 of the flapbody 164 in the inboard direction. The spar extension portion 150 is astructural member, or load-bearing element, of the torque member 108.

The spar major portion 148 and the spar extension portion 150 areintegrally formed as a single part, or single piece, that forms aunitary structure or body of the spar 106. The spars 106 may be formedof any suitable structural material. In an example, the spars 106 areformed of a metallic material. In an example, the spars 106 are formedof a composite material. An example of a composite material is afiber-reinforced polymer that includes a polymer matrix (e.g., athermoset resin or a thermoplastic polymer) that is reinforced withfibers (e.g., glass, carbon, aramid, etc.). As an example, the compositematerial is a carbon fiber reinforced polymer.

In an example, at least one of the upper skin 102 and the lower skin 104includes a skin major portion 152 and a skin extension portion 154 thatextends from the skin major portion 152. The flap body 164 is partiallyformed by the skin major portion 152 and the torque member 108 ispartially formed by the skin extension portion 154.

In an example, the skin major portion 152 extends in a span-wisedirection between the outboard end 126 and the inboard end 124 of theflap body 164 and in the chord-wise direction between the leading end112 and the trailing end 116 of the flap body 164. The skin extensionportion 154 extends from the inboard end 124 of the flap body 164 in theinboard direction.

The skin major portion 152 and the skin extension portion 154 areintegrally formed as a single part, or single piece, that forms aunitary body of the upper skin 102 an/or the lower skin 104. The upperskin 102 an/or the lower skin 104 may be formed of any suitablestructural material. In an example, the upper skin 102 an/or the lowerskin 104 are formed of a metallic material. In an example, the upperskin 102 an/or the lower skin 104 are formed of a composite material. Anexample of a composite material is a fiber-reinforced polymer thatincludes a polymer matrix (e.g., a thermoset resin or a thermoplasticpolymer) that is reinforced with fibers (e.g., glass, carbon, aramid,etc.). As an example, the composite material is a carbon fiberreinforced polymer.

In an example, the torque member 108 is formed by the spar extensionportion 150 of one of the spars 106. In an example, the torque member108 is formed by the spar extension portion 150 of two of the spars 106.In an example, the torque member 108 is formed by the spar extensionportion 150 of three of the spars 106. In an example, the torque member108 is formed by the spar extension portion 150 of one of the spars 106and an extension member 146 (FIG. 14) that is coupled to the flap body164. In an example, the torque member 108 is formed by the sparextension portion 150 of two of the spars 106 and the extension member146. In an example, the torque member 108 is formed by the sparextension portion 150 of two of the spars 106 and at least one extensionrib 176 (FIG. 13) that is coupled to the spar extension portion 150 oftwo of the spars 106. In an example, the torque member 108 is formed bythe spar extension portion 150 of one of the spars 106, the sparextension portion 150, and at least one extension rib 176. In any ofthese examples, the torque member 108 may also be formed by the skinextension portion 154 of at least one of the upper skin 102 and/or thelower skin 104.

In an example, and as best illustrated in FIG. 3, the spar extensionportion 150 of a first one of the spars 106 forms the front wall 156 ofthe torque member 108, the spar extension portion 150 of a second one ofthe spars 106 forms the rear wall 158 of the torque member 108, the skinextension portion 154 of the upper skin 102 forms the upper wall 160 ofthe torque member 108, and the skin extension portion 154 of the lowerskin 104 forms the lower wall 162 of the torque member 108. The sparmajor portion 148 of the first one of the spars 106 and the second oneof the spars 106 (not visible in FIG. 3) and the skin extension portion154 of the upper skin 102 and the lower skin 104 at least partially formthe flap structure of the flap body 164.

Referring to FIG. 8, in an example, the flap body 164 also includesadditional structural elements. In an example, the flap body 164 alsoincludes additional ones of the spars 106 extending between the outboardend 126 and the inboard end 124 of the flap body 164. In an example, theflap body 164 also includes a plurality of ribs 166 (also referred toindividually as rib 166) extending between the upper skin 102 and thelower skin 104. In an example, the ribs 166 extend in a chord-wisedirection between adjacent pairs of the spars 106.

Referring to FIGS. 9-18, in an example, the plurality of spars 106includes a front spar 110 that is located proximate to the leading end112 of the flap body 164. In an example, the plurality of spars 106 alsoincludes a rear spar 114 that is located proximate to the trailing end116 of the wing flap 100. In an example, the plurality of spars 106 alsoincludes a middle spar 118 that is located between the front spar 110and the rear spar 114. In FIGS. 9-18, the upper skin 102 is not shown.

Referring to FIGS. 9-14, in examples of the disclosed wing flap 100, thefront spar 110 includes a front-spar major portion 120 and a front-sparextension portion 122 that extends coaxially from the front-spar majorportion 120 in the inboard direction. The flap body 164 is partiallyformed by the front-spar major portion 120. The torque member 108 ispartially formed by the front-spar extension portion 122. In an example,the front-spar major portion 120 extends between the inboard end 124 andthe outboard end 126 of the flap body 164 and the front-spar extensionportion 122 extends between the outboard end 178 and the inboard end 180of the torque member 108. Utilization of the front spar 110 as a commonstructural member of the wing flap 100 that integrally forms the torquemember 108 with the flap body 164 naturally positions the torque member108 toward or proximate to the leading end 112 of the flap body 164.

Referring to FIG. 9, in an example, the wing flap 100 includes the frontspar 110, the middle spar 118, and the rear spar 114. The flap body 164is partially formed by the front-spar major portion 120. The torquemember 108 is partially formed by the front-spar extension portion 122.In an example, the front-spar major portion 120 extends between theinboard end 124 and the outboard end 126 of the flap body 164 and thefront-spar extension portion 122 extends between the outboard end 178and the inboard end 180 of the torque member 108.

In an example, the middle spar 118 includes a middle-spar major portion132 and a middle-spar extension portion 134 that extends coaxially fromthe middle-spar major portion 132 in the inboard direction. The flapbody 164 is partially formed by the middle-spar major portion 132. Thetorque member 108 is partially formed by the middle-spar extensionportion 134. In an example, the middle-spar major portion 132 extendsbetween the inboard end 124 and the outboard end 126 of the flap body164 and the middle-spar extension portion 134 extends between theoutboard end 178 and the inboard end 180 of the torque member 108.

In an example, the rear spar 114, and/or any additional ones of thespars 106, terminates at the inboard end 124 of the flap body 164. In anexample, the rear spar 114 extends between the outboard end 126 and theinboard end 124 of the flap body 164 and terminates at the inboard end124 of the flap body 164. The flap body 164 is partially formed by therear spar 114.

In an example, the wing flap 100 also includes one or more inboard ribs168 (also referred to individually as inboard rib 168) located at theinboard end 124 of the flap body 164. The inboard rib 168 is an exampleof one of the ribs 166 (FIG. 8). In an example, the inboard rib 168extends between adjacent pairs of the spars 106. In an example, theinboard rib 168 is located proximate to a transition between the sparmajor portion 148 and the spar extension portion 150 of the adjacentpair of spars 106. The inboard ribs 168 are configured to redistributeloads between the spars 106.

In an example, the wing flap 100 includes a first one of the inboardribs 168 that extends between and that is coupled to the front spar 110and the middle spar 118. For example, the first one of the inboard ribs168 has one end that is located proximate to a transition of thefront-spar major portion 120 and the front-spar extension portion 122and an opposite end that is located proximate to a transition of themiddle-spar major portion 132 and the middle-spar extension portion 134.In an example, the wing flap 100 also includes a second one of theinboard ribs 168 that extends between and that is coupled to the middlespar 118 and the rear spar 114. For example, the second one of theinboard ribs 168 has one end that is located proximate to a transitionof the middle-spar major portion 132 and the middle-spar extensionportion 134 and an opposite end that is located proximate to a terminalend of the rear spar 114 (e.g., at the inboard end 124 of the flap body164).

In an example, two or more of the spars 106 are parallel to one another.In an example, adjacent pairs of the spars 106 are parallel to eachother. As used herein, the term “parallel” has its ordinary meaning asknown to those skilled in the art and refers to a condition in which afirst line, extending longitudinally through the one of the spars 106,and a second line, extending longitudinally through the another one ofthe spars 106, share a common plane and the first line and the secondline being equidistant from one another. As used herein, the term“parallel” includes exactly parallel and approximately parallel (i.e.,close to parallel that still performs the desired function or achievesthe desired result).

Referring to FIGS. 10 and 11, in an example, the wing flap 100 includesthe front spar 110, the middle spar 118, and the rear spar 114. The flapbody 164 is partially formed by the front-spar major portion 120 and themiddle-spar major portion 132. The torque member 108 is partially formedby the front-spar extension portion 122 and the middle-spar extensionportion 134. In an example, the front-spar major portion 120 and themiddle-spar major portion 132 extend between the inboard end 124 and theoutboard end 126 of the flap body 164 and the front-spar extensionportion 122 and the middle-spar extension portion 134 extend between theoutboard end 178 and the inboard end 180 of the torque member 108.

In an example, the rear spar 114 includes a rear-spar major portion 128and a rear-spar extension portion 130 that extends coaxially from therear-spar major portion 128. The flap body 164 is partially formed bythe rear-spar major portion 128. The torque member 108 is partiallyformed by the rear-spar extension portion 130. In an example, therear-spar major portion 128 extends between the inboard end 124 and theoutboard end 126 of the flap body 164 and the rear-spar extensionportion 130 extends from the outboard end 178 to the inboard end 180 ofthe torque member 108.

In an example, two or more of the spars 106 are not parallel to oneanother. In an example, adjacent pairs of the spars 106 are not parallelto each other. In an example, two or more of the spars 106 convergetoward each other proximate to (e.g., at or near) the inboard end 180 ofthe torque member 108. For example, at least two of the front spar 110,the middle spar 118, and the rear spar 114 converge toward one anotherproximate to the inboard end 180 of the torque member 108.

In an example, the front spar 110, the middle spar 118, and the rearspar 114 converge toward one another proximate to the inboard end 180 ofthe torque member 108. The front spar 110, the middle spar 118, and therear spar 114 converging toward one another reduces the distance betweenthe front spar 110 and the middle spar 118 and reduces the distancebetween the middle spar 118 and the rear spar 114 at the inboard end 124of the flap body 164 and at the inboard end 180 of the torque member108. Reducing the distance between the front spar 110 and the middlespar 118 may eliminate the need for the inboard rib 168 extendingbetween the front spar 110 and the middle spar 118 (FIG. 9). Reducingthe distance between the middle spar 118 and the rear spar 114 mayeliminate the need for the inboard rib 168 extending between the middlespar 118 and the rear spar 114 (FIG. 9).

Referring to FIG. 10, in an example, the middle spar 118 is oriented atan acute angle relative to a line that is normal to and that extendsfrom the front spar 110 such that the middle spar 118 is directed towardthe front spar 110 proximate to the inboard end 180 of the torque member108. The rear spar 114 is oriented at an acute angle relative to a linethat is normal to and that extends from the middle spar 118 such thatthe rear spar 114 is directed toward the middle spar 118 proximate tothe inboard end 180 of the torque member 108.

Referring to FIG. 11, in an example, the middle spar 118 is oriented atan acute angle relative to a line that is normal to and that extendsfrom the front spar 110 such that the middle spar 118 is directed towardthe front spar 110 proximate to the inboard end 180 of the torque member108. A first segment 114A of the rear spar 114 is oriented parallel tothe front spar 110. A second segment 114B of the rear spar 114 isoriented at an acute angle relative to a line that is normal to and thatextends from the middle spar 118 such that the second segment 114B ofthe rear spar 114 is directed toward the middle spar 118 proximate tothe inboard end 180 of the torque member 108.

In an example, the spars 106 converge toward the leading end 112 of theflap body 164, as illustrated in FIGS. 10 and 11. In some otherexamples, the spars 106 converge toward the trailing end 116 of the flapbody 164.

In an example, the wing flap 100 includes the front spar 110, the middlespar 118, and the rear spar 114. The flap body 164 is partially formedby the front-spar major portion 120, the middle spar 118, and therear-spar major portion 128. The torque member 108 is partially formedby the front-spar extension portion 122 and the rear-spar extensionportion 130. In an example, the front-spar major portion 120, the middlespar 118, and the rear-spar major portion 128 extend between the inboardend 124 and the outboard end 126 of the flap body 164 and the front-sparextension portion 122 and the rear-spar extension portion 130 extendbetween the outboard end 178 and the inboard end 180 of the torquemember 108. The front spar 110 and the rear spar 114 converge toward oneanother proximate to the inboard end 180 of the torque member 108. Thefront spar 110 and the rear spar 114 converging toward one anotherreduces the distance between the front spar 110 and the rear spar 114 atthe inboard end 124 of the flap body 164 and at the inboard end 180 ofthe torque member 108.

In an example, the wing flap 100 includes the front spar 110 and therear spar 114. The flap body 164 is partially formed by the front-sparmajor portion 120 and the rear-spar major portion 128. The torque member108 is partially formed by the front-spar extension portion 122 and therear-spar extension portion 130. In an example, the front-spar majorportion 120 and the rear-spar major portion 128 extend between theinboard end 124 and the outboard end 126 of the flap body 164 and thefront-spar extension portion 122 and the rear-spar extension portion 130extend between the outboard end 178 and the inboard end 180 of thetorque member 108. The front spar 110 and the rear spar 114 convergetoward one another proximate to the inboard end 180 of the torque member108. The front spar 110 and the rear spar 114 converging toward oneanother reduces the distance between the front spar 110 and the rearspar 114 at the inboard end 124 of the flap body 164 and at the inboardend 180 of the torque member 108.

Referring to FIG. 12, in an example, the wing flap 100 includes thefront spar 110, the middle spar 118, and the rear spar 114. The flapbody 164 is partially formed by the front-spar major portion 120, themiddle-spar major portion 132, and the rear spar 114. The torque member108 is partially formed by the front-spar extension portion 122 and themiddle-spar extension portion 134. In an example, the front-spar majorportion 120, the middle-spar major portion 132, and the rear spar 114extend between the inboard end 124 and the outboard end 126 of the flapbody 164 and the front-spar extension portion 122 and the middle-sparextension portion 134 extend between the outboard end 178 and theinboard end 180 of the torque member 108.

In an example, the wing flap 100 also includes the extension member 146that is coupled to the flap body 164 and that is located between thefront-spar extension portion 122 of the front spar 110 and themiddle-spar extension portion 134 of the middle spar 118. The torquemember 108 is partially formed by the extension member 146.

In an example, the extension member 146 extends outward from the inboardend 124 of the flap body 164 in the inboard direction to the inboard end180 of the torque member 108. The extension member 146 is coupled to theflap body 164 in any suitable manner sufficient to transfer actuationforces from the flap support mechanism 212 (FIG. 1) to the flap body 164via the torque member 108.

In an example, the extension member 146 is coupled to the inboard rib168 that extends between and that is coupled to the front spar 110 andthe middle spar 118. In an example, the inboard rib 168 includes astiffener, or flange, that is vertically oriented and that is located onan inboard face of the inboard rib 168. The extension member 146 isfastened (e.g., bolted) to the stiffener of the inboard rib 168. Anyother suitable joint may be used to couple an outboard end of theextension member 146 to the inboard rib 168. The extension member 146and the inboard rib 168 may be formed of any suitable structuralmaterial. In an example, one or both of the extension member 146 and theinboard rib 168 are formed of a metallic material. In an example, one orboth of the extension member 146 and the inboard rib 168 are formed of acomposite material (e.g., carbon fiber reinforced polymer).

Referring to FIG. 13, in an example, the wing flap 100 includes thefront spar 110, the middle spar 118, and the rear spar 114. The flapbody 164 is partially formed by the front-spar major portion 120, themiddle-spar major portion 132, and the rear spar 114. The torque member108 is partially formed by the front-spar extension portion 122 and themiddle-spar extension portion 134. In an example, the front-spar majorportion 120, the middle-spar major portion 132, and the rear spar 114extend between the inboard end 124 and the outboard end 126 of the flapbody 164 and the front-spar extension portion 122 and the middle-sparextension portion 134 extend between the outboard end 178 and theinboard end 180 of the torque member 108.

In an example, the wing flap 100 also includes an extension rib 176 thatextends between and that is coupled to the front-spar extension portion122 of the front spar 110 and the middle-spar extension portion 134 ofthe middle spar 118. The torque member 108 is partially formed by theextension rib 176.

In an example, the extension rib 176 is located at any one of variouslocations between the outboard end 178 and the inboard end 180 of thetorque member 108. The extension rib 176 is configured to redistributeloads between the front-spar extension portion 122 of the front spar 110and the middle-spar extension portion 134 of the middle spar 118 duringactuation of the wing flap 100. In an example, the extension rib 176extends between and/or is coupled to the upper skin 102 and/or the lowerskin 104.

In an example, the wing flap 100 includes a plurality of extension ribs176, as illustrated in FIG. 13. In an example, the extension ribs 176are equally spaced along the torque member 108 between the outboard end178 and the inboard end 180 of the torque member 108. The number ofextension ribs 176 may vary depending, for example, on the loads appliedto the torque member 108, failsafe requirements of the torque member108, and required stiffness of the torque member 108. In an example, oneof the extension ribs 176 is located proximate to the inboard end 180 ofthe torque member 108. In an example, at least one other of theextension ribs 176 is located between the outboard end 178 and theinboard end 180 of the torque member 108, for example, between the oneof the extension ribs 176 located at the inboard end 180 of the torquemember 108 and the inboard rib 168.

Referring to FIG. 14, in an example, the wing flap 100 includes thefront spar 110 and the rear spar 114. The flap body 164 is partiallyformed by the front-spar major portion 120 and the rear spar 114. Thetorque member 108 is partially formed by the front-spar extensionportion 122. In an example, the front-spar major portion 120 and therear spar 114 extend between the inboard end 124 and the outboard end126 of the flap body 164 and the front-spar extension portion 122extends between the outboard end 178 and the inboard end 180 of thetorque member 108.

In an example, the wing flap 100 also includes the inboard rib 168 thatextends between the front spar 110 and the rear spar 114 at the inboardend 124 of the flap body 164. In an example, the wing flap 100 alsoincludes the extension member 146 that is coupled to the inboard rib168. The torque member 108 is partially formed by the extension member146.

While not illustrated in FIG. 14, in an example, the wing flap 100 alsoincludes at least one extension rib 176 (FIG. 13) that extends betweenthe front-spar extension portion 122 of the front spar 110 and theextension member 146. The torque member 108 is partially formed by theextension rib 176 and the extension member 146.

Referring to FIGS. 15-18, in examples of the disclosed wing flap 100,the rear spar 114 includes the rear-spar major portion 128 and therear-spar extension portion 130 that extends coaxially from therear-spar major portion 128 in the inboard direction. The flap body 164is partially formed by the rear-spar major portion 128. The torquemember 108 is partially formed by the rear-spar extension portion 130.In an example, the rear-spar major portion 128 extends between theinboard end 124 and the outboard end 126 of the flap body 164 and therear-spar extension portion 130 extends between the outboard end 178 andthe inboard end 180 of the torque member 108. Utilization of the rearspar 114 as a common structural member of the wing flap 100 thatintegrally forms the torque member 108 with the flap body 164 naturallypositions the torque member 108 toward or proximate to the trailing end116 of the flap body 164.

Referring to FIG. 15, in an example, the wing flap 100 includes thefront spar 110, the middle spar 118, and the rear spar 114. The flapbody 164 is partially formed by the rear-spar major portion 128. Thetorque member 108 is partially formed by the rear-spar extension portion130. In an example, the rear-spar major portion 128 extends between theinboard end 124 and the outboard end 126 of the flap body 164 and therear-spar extension portion 130 extends between the outboard end 178 andthe inboard end 180 of the torque member 108.

In an example, the middle spar 118 includes the middle-spar majorportion 132 and the middle-spar extension portion 134 that extendscoaxially from the middle-spar major portion 132 in the inboarddirection. The flap body 164 is partially formed by the middle-sparmajor portion 132. The torque member 108 is partially formed by themiddle-spar extension portion 134. In an example, the middle-spar majorportion 132 extends between the inboard end 124 and the outboard end 126of the flap body 164 and the middle-spar extension portion 134 extendsbetween the outboard end 178 and the inboard end 180 of the torquemember 108.

In an example, the front spar 110, and/or any additional ones of thespars 106, terminates at the inboard end 124 of the flap body 164. In anexample, the front spar 110 extends between the outboard end 126 and theinboard end 124 of the flap body 164 and terminates at the inboard end124 of the flap body 164. The flap body 164 is partially formed by thefront spar 110.

In an example, the wing flap 100 also includes one or more of theinboard ribs 168 located at the inboard end 124 of the flap body 164. Inan example, the wing flap 100 includes a first one of the inboard ribs168 that extends between and that is coupled to the rear spar 114 andthe middle spar 118. For example, the first one of the inboard ribs 168has one end that is located proximate to a transition of the rear-sparmajor portion 128 and the rear-spar extension portion 130 and anopposite end that is located proximate to a transition of themiddle-spar major portion 132 and the middle-spar extension portion 134.In an example, the wing flap 100 also includes a second one of theinboard ribs 168 that extends between and that is coupled to the middlespar 118 and the front spar 110. For example, the second one of theinboard ribs 168 has one end that is located proximate to a transitionof the middle-spar major portion 132 and the middle-spar extensionportion 134 and an opposite end that is located proximate to a terminalend of the front spar 110 (e.g., at the inboard end 124 of the flap body164).

Referring to FIG. 16, in an example, the wing flap 100 includes thefront spar 110, the middle spar 118, and the rear spar 114. The flapbody 164 is partially formed by the rear-spar major portion 128, themiddle-spar major portion 132, and the front spar 110. The torque member108 is partially formed by the rear-spar extension portion 130 and themiddle-spar extension portion 134. In an example, the rear-spar majorportion 128, the middle-spar major portion 132, and the front spar 110extend between the inboard end 124 and the outboard end 126 of the flapbody 164 and the rear-spar extension portion 130 and the middle-sparextension portion 134 extend between the outboard end 178 and theinboard end 180 of the torque member 108.

In an example, the wing flap 100 also includes the extension member 146that is coupled to the flap body 164 and that is located between therear-spar extension portion 130 of the rear spar 114 and the middle-sparextension portion 134 of the middle spar 118. The torque member 108 ispartially formed by the extension member 146.

In an example, the extension member 146 extends outward from the inboardend 124 of the flap body 164 in the inboard direction to the inboard end180 of the torque member 108. In an example, the extension member 146 iscoupled to the inboard rib 168 that extends between and that is coupledto the rear spar 114 and the middle spar 118. The extension member 146is coupled to the flap body 164 in any suitable manner sufficient totransfer actuation forces from the flap support mechanism 212 (FIG. 1)to the flap body 164 via the torque member 108.

Referring to FIG. 17, in an example, the wing flap 100 includes thefront spar 110, the middle spar 118, and the rear spar 114. The flapbody 164 is partially formed by the rear-spar major portion 128, themiddle-spar major portion 132, and the front spar 110. The torque member108 is partially formed by the rear-spar extension portion 130 and themiddle-spar extension portion 134. In an example, the rear-spar majorportion 128, the middle-spar major portion 132, and the front spar 110extend between the inboard end 124 and the outboard end 126 of the flapbody 164 and the rear-spar extension portion 130 and the middle-sparextension portion 134 extend between the outboard end 178 and theinboard end 180 of the torque member 108.

In an example, the wing flap 100 also includes the extension rib 176that extends between and that is coupled to the rear-spar extensionportion 130 of the rear spar 114 and the middle-spar extension portion134 of the middle spar 118. The torque member 108 is partially formed bythe extension rib 176.

In an example, the extension rib 176 is located at any one of variouslocations between the outboard end 178 and the inboard end 180 of thetorque member 108. The extension rib 176 is configured to redistributeloads between the rear-spar extension portion 130 of the rear spar 114and the middle-spar extension portion 134 of the middle spar 118 duringactuation of the wing flap 100. In an example, the wing flap 100includes a plurality of extension ribs 176, as illustrated in FIG. 17.In an example, the extension ribs 176 are equally spaced along thetorque member 108 between the outboard end 178 and the inboard end 180of the torque member 108.

Referring to FIG. 18, in an example, the wing flap 100 includes thefront spar 110 and the rear spar 114. The flap body 164 is partiallyformed by the rear-spar major portion 128 and the front spar 110. Thetorque member 108 is partially formed by the rear-spar extension portion130. In an example, the rear-spar major portion 128 and the front spar110 extend between the inboard end 124 and the outboard end 126 of theflap body 164 and the rear-spar extension portion 130 extends betweenthe outboard end 178 and the inboard end 180 of the torque member 108.

In an example, the wing flap 100 also includes the inboard rib 168 thatextends between the front spar 110 and the rear spar 114 at the inboardend 124 of the flap body 164. In an example, the wing flap 100 alsoincludes the extension member 146 that is coupled to the inboard rib168. The torque member 108 is partially formed by the extension member146.

While not illustrated in FIG. 18, in an example, the wing flap 100 alsoincludes at least one extension rib 176 (FIG. 17) that extends betweenthe rear-spar extension portion 130 of the rear spar 114 and theextension member 146. The torque member 108 is partially formed by theextension rib 176 and the extension member 146.

In the examples shown in FIGS. 9,12, and 13, the front-spar extensionportion 122 of the front spar 110 forms the front wall 156 (FIG. 3) ofthe torque member 108 and the middle-spar extension portion 134 of themiddle spar 118 forms the rear wall 158 (FIG. 3) of the torque member108. In the examples shown in FIGS. 10 and 11, the front-spar extensionportion 122 of the front spar 110 forms the front wall 156 of the torquemember 108 and rear-spar extension portion 130 of the rear spar 114forms the rear wall 158 of the torque member 108. In the example shownin FIG. 14, the front-spar extension portion 122 of the front spar 110forms the front wall 156 of the torque member 108 and the extensionmember 146 forms the rear wall 158 of the torque member 108.

In the examples shown in FIGS. 15-17, the rear-spar extension portion130 of the rear spar 114 forms the rear wall 158 (FIG. 3) of the torquemember 108 and the middle-spar extension portion 134 of the middle spar118 forms the front wall 156 (FIG. 3) of the torque member 108. In theexample shown in FIG. 18, the rear-spar extension portion 130 of therear spar 114 forms the rear wall 158 of the torque member 108 and theextension member 146 forms the front wall 156 of the torque member 108.

In the examples shown in FIGS. 9-18, the skin extension portion 154 ofthe upper skin 102 (not visible), also referred to as upper-skinextension portion, forms the upper wall 160 (FIG. 3) of the torquemember 108 and the skin extension portion 154 of the lower skin 104,also referred to as lower-skin extension portion, forms the lower wall162 of the torque member 108. The skin major portion 152 of the upperskin 102, also referred to as upper-skin major portion, forms an upperskin panel of the flap body 164 and the skin major portion 152 of thelower skin 104, also referred to as lower-skin major portion, forms alower skin panel of the flap body 164.

Referring to FIG. 19, in an example, one or both of the upper skin 102and/or the lower skin 104 partially form only the flap body 164. In anexample, one or both of the upper skin 102 and/or the lower skin 104extends between the outboard end 126 and the inboard end 124 of the flapbody 164 and terminates at the inboard end 124 of the flap body 164.

In an example, the wing flap 100 also includes an upper-skin extensionmember 194 that takes the place of the upper-skin extension portion. Inan example, the upper-skin extension member 194 extends between theinboard end 180 and the outboard end 178 of the torque member 108 and iscoupled to the spar extension portion 150 of at least one of the spars106, for example, an adjacent pair of the spars 106 or the spar 106 andthe extension member 146. The torque member 108 is partially formed bythe upper-skin extension member 194.

In an example, the wing flap 100 also includes a lower-skin extensionmember 196 that takes the place of the lower-skin extension portion. Inan example, the lower-skin extension member 196 extends between theinboard end 180 and the outboard end 178 of the torque member 108 and iscoupled to the spar extension portion 150 of at least one of the spars106, for example, an adjacent pair of the spars 106 or the spar 106 andthe extension member 146. The torque member 108 is partially formed bythe lower-skin extension member 196.

In the illustrated examples, the skin extension portion 154 of the upperskin 102 and the lower skin 104, the upper-skin extension member 194,and the lower-skin extension member 196 extend all the way to andterminate at the inboard end 180 of the torque member 108. In otherexamples, one or more of the skin extension portion 154 of the upperskin 102 and the lower skin 104, the upper-skin extension member 194,and/or the lower-skin extension member 196 terminates prior to theinboard end 180 of the torque member 108. In an example, the skinextension portion 154 of the upper skin 102 and the lower skin 104, theupper-skin extension member 194, and/or the lower-skin extension member196 extends at least to a point on the torque member 108 in which thetorque member 108 enters the fuselage 202 through the opening 206 (FIG.4).

In some aerospace implementations, failsafe measures may be beneficialto ensure continued safe flight and landing. An example of a failsafemeasure is to have a redundant load path that is not utilized untilfailure of a primary load path. Another example of a failsafe measure isto have two or more load paths in which failure of any one of the loadpaths redistributes the load to another one of the load paths, each ofwhich is capable of reacting to the entire load. Another example of afailsafe measure is to have adequate reserve loading capability in eachof the structural members defining a given load path such that the loadpath is capable to react to the entire load after failure, damage, orother impairment to one of the structural members.

In some examples, such as the illustrative examples shown in FIGS. 10-12and 16, the torque member 108 of the disclosed wing flap 100 includes afailsafe configuration. In an example, the spar extension portion 150 oftwo adjacent spars 106 may form redundant load paths. In an example, theextension member 146 and the spar extension portion 150 of an adjacentspar 106 may form redundant load paths. In an example (FIGS. 10 and 11),the front-spar extension portion 122 and the middle-spar extensionportion 134 define a first load path, the middle-spar extension portion134 and the rear-spar extension portion 130 define a second load path,and the front-spar extension portion 122 and the rear-spar extensionportion 130 define a third load path. In an example (FIG. 12), thefront-spar extension portion 122 and the extension member 146 define afirst load path, the extension member 146 and the rear-spar extensionportion 130 define a second load path, and the front-spar extensionportion 122 and the rear-spar extension portion 130 define a third loadpath. In an example (FIG. 16), the middle-spar extension portion 134 andthe extension member 146 define a first load path, the extension member146 and the rear-spar extension portion 130 define a second load path,and the middle-spar extension portion 134 and the rear-spar extensionportion 130 define a third load path. In these examples, each one of theload paths is capable of reacting to the entire load applied to the wingflap 100 and a failure in one of the load paths (e.g., resulting fromdamage to one of the spars 106) may be redistributed to the other loadpath. In an example, one of the redundant load paths is loaded andanother one of the redundant load paths is unloaded. Upon a failure inthe loaded load path, the load is distributed to the unloaded load path.In an example, each one of the redundant load paths is loaded and eitherone of the loaded load paths is capable of reacting to the entire loadupon failure of the other.

In some examples, such as the illustrative examples shown in FIGS. 9,13-15, 17, and 18, the torque member 108 of the disclosed wing flap 100may also include a failsafe configuration. In an example, the sparextension portion 150 of each one of the spars 106 has a reserve loadingcapacity that exceeds the entire load applied to the wing flap 100. Inan example, the spar extension portion 150 of the spar 106 and theextension member 146 each has a reserve loading capacity that exceedsthe entire load applied to the wing flap 100. In an example (FIGS. 9 and13), the front-spar extension portion 122 and the middle-spar extensionportion 134 define the load path and each one of the front-sparextension portion 122 and the middle-spar extension portion 134 has areserve loading capacity that exceeds the entire load applied to thewing flap 100. In an example (FIGS. 15 and 17), the middle-sparextension portion 134 and the rear-spar extension portion 130 define theload path and each one of the middle-spar extension portion 134 and therear-spar extension portion 130 has a reserve loading capacity thatexceeds the entire load applied to the wing flap 100. In an example(FIG. 14), the front-spar extension portion 122 and the extension member146 define the load path and each one of the front-spar extensionportion 122 and the extension member 146 has a reserve loading capacitythat exceeds the entire load applied to the wing flap 100. In an example(FIG. 18), the rear-spar extension portion 130 and the extension member146 define the load path and each one of the rear-spar extension portion130 and the extension member 146 has a reserve loading capacity thatexceeds the entire load applied to the wing flap 100.

Referring to FIG. 20, also disclosed is an example method 1000. In anexample, the method 1000 is utilized for forming the wing flap 100. Inan example, the method 1000 includes a step of integrally forming thetorque member 108 with at least a portion of the flap body 164 to formthe wing flap 100 (Block 1002). The flap body 164 is configured to bemovably coupled with the wing 214 of the aircraft 200. The torque member108 is configured to be operatively coupled with the flap actuator 260of the aircraft 200.

In an example, the method 1000 includes a step of providing the lowerskin 104, the upper skin 102, and the plurality of spars 106 (Block1004). As used herein, the term “providing” does not require anyparticular delivery or receipt of the provided item. Rather, the term“providing” is used to refer to items that are available for use or thatare otherwise in a state or condition of being ready for use. At leastone of the plurality of spars 106 includes the spar major portion 148and the spar extension portion 150 that extends from the spar majorportion 148.

In an example, the method 1000 includes a step of joining the lower skin104, the upper skin 102, and the plurality of spars 106 together (Block1006). Various methods or operations may be utilized to join the lowerskin 104, the upper skin 102, and the plurality of spars 106 including,but not limited to, fastening, co-curing, bonding, or combinationsthereof.

In an example, the method 1000 includes steps of partially forming theflap body 164 with the spar major portion 148 of a first one of theplurality of spars 106 (Block 1008) and partially forming the torquemember 108 with the spar extension portion 105 of the first one of theplurality of spars 106 (Block 1010).

In an example, the method 1000 includes steps of partially forming theflap body 164 with the spar major portion 148 of a second one of theplurality of spars 106 (Block 1012) and partially forming the torquemember 108 with the spar extension portion 150 of the second one of theplurality of spars 106 (Block 1014). Alternatively, the method 10000includes steps of partially forming the flap body 164 with a third oneof the plurality of spars 106 (Block 1016) and partially forming thetorque member 108 with the extension member 146 that is coupled to theflap body 164 (Block 1020). In an example, the method 1000 includes astep of partially forming the flap body 164 with a fourth one of theplurality of spars 106.

In an example, the method 1000 includes steps of partially forming theflap body 164 with the skin major portion 152 of the upper skin 102(Block 1022) and partially forming the torque member 108 with the skinextension portion 154 of the upper skin 102 (Block 1024). Alternatively,the method 1000 includes steps of partially forming the flap body 164with the upper skin 102 (Block 1026) and partially forming the torquemember 108 with the upper-skin extension member 194 (Block 1028).

In an example, the method 1000 includes steps of partially forming theflap body 164 with the skin major portion 152 of the lower skin 104(Block 1030) and partially forming the torque member 108 with the skinextension portion 154 of the lower skin 104 (Block 1032). Alternatively,the method 1000 includes steps of partially forming the flap body 164with the lower skin 104 (Block 1034) and partially forming the torquemember 108 with the lower-skin extension member 196 (Block 1036).

In an example, the method 1000 is further utilized for forming the wing214 of the aircraft 200. In an example, the method 1000 includes a stepof movably coupling the flap body 164 of the wing flap 100 to the wingbody 258 of the wing 214 at the trailing edge 242 of the wing 214 (Block1038). In accordance with the method 1000, the wing flap 100 may becoupled to the wing 214 during manufacture of the wing 214.Alternatively, in accordance with the method 1000, a conventionalinboard flap of the aircraft 200 may be replaced with the wing flap 100,such as during maintenance or repair of the aircraft 200.

In an example, the method 1000 is further utilized for forming theaircraft 200. In an example, the method 1000 includes a step of couplingthe wing 214 to the fuselage 202 of the aircraft 200 (Block 1040). In anexample, the method 1000 includes a step of operatively coupling theinboard end 180 of the torque member 108 with the flap actuator 260(Block 1042). In an example, the torque member 108 extends into thefuselage 202 through the opening 206 in the fuselage 202.

In an example, the method 1000 is also utilized for operating the wingflap 100. In an example, the method 1000 includes a step of actuatingthe wing flap 100 between the raised and lowered positions (Block 1044).In an example, the flap actuator 260 pivots and/or translates the flapbody 164 of the wing flap 100 relative to the wing 214 via the torquemember 108.

Examples of the wing flap 100 and method 1000 disclosed herein may finduse in a variety of potential applications, particularly in thetransportation industry, including for example, aerospace applications.Referring now to FIGS. 1 and 21, examples of the wing flap 100 andmethod 1000 may be used in the context of an aircraft manufacturing andservice method 1100, as shown in the flow diagram of FIG. 21, and theaircraft 200, as shown in FIG. 1. Aircraft applications of the disclosedexamples may include formation of the wing flap 100 and use of the wingflap 100 as a flight control surface of the aircraft 200.

As shown in FIG. 21, during pre-production, the illustrative method 1100may include specification and design of the aircraft 200 (Block 1102)and material procurement (Block 1104). During production of the aircraft200, component and subassembly manufacturing (Block 1106) and systemintegration (Block 1108) of the aircraft 200 may take place. Thereafter,the aircraft 200 may go through certification and delivery (Block 1110)to be placed in service (Block 1112). The disclosed wing flap 100 andmethod 1000 may form a portion of component and subassemblymanufacturing (Block 1106) and/or system integration (Block 1108).Routine maintenance and service (Block 1114) may include modification,reconfiguration, refurbishment, etc. of one or more systems of theaircraft 200, such as repair and/or replacement of inboard wing flaps.

Each of the processes of illustrative method may be performed or carriedout by a system integrator, a third party, and/or an operator (e.g., acustomer). For the purposes of this description, a system integrator mayinclude, without limitation, any number of aircraft manufacturers andmajor-system subcontractors; a third party may include, withoutlimitation, any number of vendors, subcontractors, and suppliers; and anoperator may be an airline, leasing company, military entity, serviceorganization, and so on.

Examples of the wing flap 100 and method 1000 shown or described hereinmay be employed during any one or more of the stages of themanufacturing and service method 1100 shown in the flow diagramillustrated by FIG. 21. For example, components or subassemblies, suchas the wing flap 100 or the wing 214, corresponding to component andsubassembly manufacturing (Block 1106) may be fabricated or manufacturedin a manner similar to components or subassemblies produced while theaircraft 200 is in service (Block 1112). Also, one or more examples ofthe wing flap 100, method 1000, or combinations thereof may be utilizedduring system integration (Block 1108) and/or certification and delivery(Block 1110). Similarly, one or more examples of the wing flap 100,method 1000, or a combination thereof, may be utilized, for example andwithout limitation, while the aircraft 200 is in service (Block 1112)and during maintenance and service (Block 1114).

Although an aerospace example is shown, the principles disclosed hereinmay be applied to other industries, such as the automotive industry.Accordingly, in addition to aircraft, the principles disclosed hereinmay apply to other vehicles, (e.g., land vehicles, marine vehicles,space vehicles, etc.).

Reference herein to “example” means that one or more feature, structure,element, component, characteristic and/or operational step described inconnection with the example is included in at least one embodiment andor implementation of the subject matter according to the presentdisclosure. Thus, the phrase “an example” and similar languagethroughout the present disclosure may, but do not necessarily, refer tothe same example. Further, the subject matter characterizing any oneexample may, but does not necessarily, include the subject mattercharacterizing any other example.

As used herein, a system, apparatus, structure, article, element,component, or hardware “configured to” perform a specified function isindeed capable of performing the specified function without anyalteration, rather than merely having potential to perform the specifiedfunction after further modification. In other words, the system,apparatus, structure, article, element, component, or hardware“configured to” perform a specified function is specifically selected,created, implemented, utilized, programmed, and/or designed for thepurpose of performing the specified function. As used herein,“configured to” denotes existing characteristics of a system, apparatus,structure, article, element, component, or hardware that enable thesystem, apparatus, structure, article, element, component, or hardwareto perform the specified function without further modification. Forpurposes of this disclosure, a system, apparatus, structure, article,element, component, or hardware described as being “configured to”perform a particular function may additionally or alternatively bedescribed as being “adapted to” and/or as being “operative to” performthat function.

Unless otherwise indicated, the terms “first”, “second”, etc. are usedherein merely as labels, and are not intended to impose ordinal,positional, or hierarchical requirements on the items to which theseterms refer. Moreover, reference to a “second” item does not require orpreclude the existence of lower-numbered item (e.g., a “first” item)and/or a higher-numbered item (e.g., a “third” item).

As used herein, “coupled”, “coupling”, and similar terms refer to two ormore elements that are joined, linked, fastened, connected, put incommunication, or otherwise associated (e.g., mechanically,electrically, fluidly, optically, electromagnetically) with one another.In various examples, the elements may be associated directly orindirectly. As an example, element A may be directly associated withelement B. As another example, element A may be indirectly associatedwith element B, for example, via another element C. It will beunderstood that not all associations among the various disclosedelements are necessarily represented. Accordingly, couplings other thanthose depicted in the figures may also exist.

As used herein, the phrase “at least one of”, when used with a list ofitems, means different combinations of one or more of the listed itemsmay be used and only one of each item in the list may be needed. Forexample, “at least one of item A, item B, and item C” may include,without limitation, item A or item A and item B. This example also mayinclude item A, item B, and item C, or item B and item C. In otherexamples, “at least one of” may be, for example, without limitation, twoof item A, one of item B, and ten of item C; four of item B and seven ofitem C; and other suitable combinations.

In FIGS. 20 and 21, referred to above, the blocks may representoperations and/or portions thereof and lines connecting the variousblocks do not imply any particular order or dependency of the operationsor portions thereof. Blocks represented by dashed lines indicatealternative operations and/or portions thereof. Dashed lines, if any,connecting the various blocks represent alternative dependencies of theoperations or portions thereof. It will be understood that not alldependencies among the various disclosed operations are necessarilyrepresented. FIGS. 20 and 21 and the accompanying disclosure describingthe operations of the disclosed methods set forth herein should not beinterpreted as necessarily determining a sequence in which theoperations are to be performed. Rather, although one illustrative orderis indicated, it is to be understood that the sequence of the operationsmay be modified when appropriate. Accordingly, modifications, additionsand/or omissions may be made to the operations illustrated and certainoperations may be performed in a different order or simultaneously.Additionally, those skilled in the art will appreciate that not alloperations described need be performed.

Although various embodiments and/or examples of the disclosed antenna,aerospace vehicle and method have been shown and described,modifications may occur to those skilled in the art upon reading thespecification. The present application includes such modifications andis limited only by the scope of the claims.

What is claimed is:
 1. A wing flap comprising: at least three spars,wherein each one of at least the three spars comprises a spar majorportion and a spar extension portion that extends from the spar majorportion; an upper skin, coupled to at least the three spars andcomprising an upper-skin major portion and an upper-skin extensionportion that extends from the upper-skin major portion; and a lowerskin, coupled to at least the three spars, opposite the upper skin, andcomprising a lower-skin major portion and a lower-skin extension portionthat extends from the lower-skin major portion, wherein: the spar majorportion of each one of at least the three spars, the upper-skin majorportion, and the lower-skin major portion at least partially define aflap body of the wing flap; the spar extension portion of each one of atleast the three spars, the upper-skin extension portion, and thelower-skin extension portion at least partially define a torque memberof the wing flap; the spar extension portion of each one of at least thethree spars is straight and is oblique to the spar extension portion ofany another one of at least the three spars; the flap body comprises aleading edge, a trailing edge that is opposite the leading edge, anoutboard end, an inboard end that is opposite the outboard end, and aflap-body width dimension between the leading edge and the trailingedge; and the torque member extends from the inboard end of the flapbody and comprises a torque-member width dimension that is less than theflap-body width dimension.
 2. The wing flap of claim 1, wherein thetorque member has a noncircular cross-sectional shape.
 3. The wing flapof claim 1, wherein: one of at least the three spars is a front spar;and the spar major portion of the front spar is located adjacent to theleading edge of the flap body.
 4. The wing flap of claim 3, wherein: oneof at least the three spars is a rear spar; and the spar major portionof the rear spar is located adjacent to the trailing edge of the flapbody.
 5. The wing flap of claim 4, wherein: one of at least the threespars is a middle spar; and the spar major portion of the middle spar islocated between the spar major portion of the front spar and the sparmajor portion of the rear spar.
 6. The wing flap of claim 5, wherein:the torque member further comprises an extension member that is coupledto the flap body, the upper-skin extension portion, and the lower-skinextension portion; and the extension member is located between the sparextension portion of the front spar and the spar extension portion ofthe middle spar or the spar extension portion of the rear spar and thespar extension portion of the middle spar.
 7. The wing flap of claim 5,wherein the torque member further comprises an extension rib that iscoupled to the spar extension portion of the front spar, the sparextension portion of the middle spar, the upper-skin extension portion,and the lower-skin extension portion.
 8. The wing flap of claim 5,wherein the torque member further comprises an extension rib that iscoupled to the spar extension portion of the rear spar, the sparextension portion of the middle spar, the upper-skin extension portion,and the lower-skin extension portion.
 9. The wing flap of claim 1,wherein: the flap body further comprises an inboard rib that is coupledto the spar major portion of at least two of at least the three spars,the upper-skin major portion, and the lower-skin major portion at theinboard end of the flap body; the torque member further comprises anextension member that is coupled to the inboard rib, the upper-skinextension portion, and the lower-skin extension portion; and theextension member is located between the spar extension portion of two ofat least the three spars.
 10. The wing flap of claim 1, wherein thetorque member further comprises an extension rib that is coupled to thespar extension portion of at least two of at least the three spars, theupper-skin extension portion, and the lower-skin extension portion. 11.The wing flap of claim 1, further comprising an inboard flap fairing,coupled to the upper-skin major portion, opposite the spar major portionof at least the three spars, wherein the inboard flap fairing is locatedproximate to the inboard end of the flap body.
 12. The wing flap ofclaim 1, further comprising a door coupled to the spar extension portionof one of at least the three spars and the lower-skin extension portion.13. The wing flap of claim 1, the spar major portion of each one of atleast the three spars runs in a straight line and is oblique to the sparmajor portion of any other one of at least the three spars.
 14. A methodfor forming a wing flap, the method comprising: at least partiallyforming a flap body of the wing flap with a spar major portion of eachone of at least three spars, an upper-skin major portion of an upperskin, and a lower-skin major portion of a lower skin; at least partiallyforming a torque member of the wing flap with a spar extension portionof each one of at least the three spars, extending from the spar majorportion of each corresponding one of at least the three spars, an upperskin extension portion of the upper skin, extending from the upper-skinmajor portion of the upper skin, and a lower-skin extension portion ofthe lower skin, extending from the lower-skin major portion of the lowerskin, wherein: the flap body comprises a leading edge, a trailing edgethat is opposite the leading edge, an outboard end, an inboard end thatis opposite the outboard end, and a flap-body width dimension betweenthe leading edge and the trailing edge; and the torque member extendsfrom the inboard end of the flap body and comprises a torque memberwidth dimension that is less than the flap-body width dimension.
 15. Awing flap, comprising: a first spar, comprising a first-spar majorportion and a first-spar extension portion that extends from thefirst-spar major portion; a second spar, comprising a second-spar majorportion and a second-spar extension portion that extends from thesecond-spar major portion; a third spar; an upper skin, coupled to thefirst spar, the second spar, and the third spar and comprising anupper-skin major portion and an upper-skin extension portion thatextends from the upper-skin major portion; and a lower skin, coupled tothe first spar, the second spar, and the third spar, opposite the upperskin, and comprising a lower-skin major portion and a lower-skinextension portion that extends from the lower-skin major portion,wherein: the first-spar major portion, the second-spar major portion,the third spar, the upper-skin major portion, and the lower-skin majorat least partially define a flap body of the wing flap; the first-sparextension portion, the second-spar extension portion, the upper-skinextension portion, and the lower-skin extension portion at leastpartially define a torque member of the wing flap; the torque membercomprises an extension rib, coupled to the first-spar extension portion,the second-spar extension portion, the upper-skin extension portion, andthe lower-skin extension portion; the flap body comprises a leadingedge, a trailing edge that is opposite the leading edge, an outboardend, an inboard end that is opposite the outboard end, and a flap-bodywidth dimension between the leading edge and the trailing edge; and thetorque member extends from the inboard end of the flap body andcomprises a torque-member width dimension that is less than theflap-body width dimension.
 16. The wing flap of claim 15, wherein: thefirst-spar major portion is located adjacent to the leading edge of theflap body; the third spar is located adjacent to the trailing edge ofthe flap body; and the second-spar major portion is located between thefirst-spar major portion and the third spar.
 17. The wing flap of claim15, wherein: the first-spar major portion is located adjacent to thetrailing edge of the flap body; the third spar is located adjacent tothe leading edge of the flap body; and the second-spar major portion islocated between the first-spar major portion and the third spar.
 18. Thewing flap of claim 15, wherein the flap body further comprises aninboard rib that is coupled to the first-spar major portion, thesecond-spar major portion, the upper-skin major portion, and thelower-skin major portion at the inboard end of the flap body.
 19. Thewing flap of claim 15, wherein the first-spar major portion and thesecond-spar major portion are straight and are parallel to each other.20. The wing flap of claim 15, wherein the first-spar extension portionand the second-spar extension portion are straight and are parallel toeach other.